Air cushion with multistage shock-absorbing assembly and fabricating method

ABSTRACT

An air cushion connected at least a cushioning element in a vertical stack configuration for absorbing both lighter and heaver heel impacts sequentially in a shoe mid-sole. The air cushion includes a first air bladder and a cushioning element forming a vertical stack configuration such that when the impact lighter than a predetermined value is applied to the vertical stack configuration, it is absorbed by deforming the first air bladder only, and when the impact heavier than the predetermined value is applied to the vertical stack configuration, it is absorbed by deforming both the first air bladder and the cushioning element.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 11/823,291, filed Jun. 27, 2007, entitled “AIR CUSHION WITHMULTISTAGE SHOCK-ABSORBING ASSEMBLY AND FABRICATING METHOD” by Jui FenShiao, which itself claims priority to and the benefit of Taiwan PatentApplications No. 095123163, filed Jun. 27, 2006, entitled “AIR CUSHIONWITH MULTISTAGE SHOCK-ABSORBING ASSEMBLY AND FABRICATING METHOD” by JulFen Shiao, the contents of which are incorporated herein in theirentireties by reference.

Some references, if any, which may include patents, patent applicationsand various publications, are cited and discussed in the description ofthis invention. The citation and/or discussion of such references isprovided merely to clarify the description of the present invention andis not an admission that any such reference is “prior art” to theinvention described herein. All references cited and discussed in thisspecification are incorporated herein by reference in their entiretiesand to the same extent as if each reference was individuallyincorporated by reference.

FIELD OF THE INVENTION

The present invention relates to an air cushion assembly adapted forabsorbing heel impacts in a shoe mid-sole, and more particularly, to anair cushion assembly having an air bladder associated with a cushioningelement in a vertical stack configuration capable of absorbing more thanone range of heel impacts against the ground.

BACKGROUND OF THE INVENTION

For most runners, initial foot impact occurs in the heel region.Therefore, the heel strike cushioning material, which is containedprincipally in the mid-sole of a running shoe, must have a firmnesswhich provides for proper impact cushioning for a person of aboutaverage weight.

U.S. Pat. No. 297,980 to Sugiyama describes a cushioning for a shoemid-sole comprised essentially of one cell having partition wallstherein.

U.S. Pat. Nos. 4,342,157 and 4,472,890 to Gilbert describes the use ofliquid-filled shock absorbing cushions in the heel portion and forefootportion of a shoe. Typical liquids include water, glycerin, and mineraloil.

When the runner is heavy, the heel cushioning material may “bottom out”before heel impact is completely absorbed, which can results inshock-related injuries. On the other hand, if the cushioning material istoo soft, poor lateral foot stability may result in injuries.

A considerable force generated during athletic activities requires thesole of an athletic shoe provide enhanced protection and shockabsorption for the feet, ankles and legs of the wearer. For example,impacts which occur during walking have been known to generate forces ofup to 1½ times the body weight at a normal walking speed, runningactivities up to 2-3 times the body weight of an individual.

For providing an air cushion with wider range of impact absorption, aneasier conventional fabrication method of air cushion is shown in FIG.1, including the steps of preparing a larger bladder 1, putting thelarger bladder 1 in a hot pressing mold 13 for forming a plurality ofribs 11 which divides the larger bladder into smaller bladders 14, 15,and 16 in a substantially horizontal configuration for providing aplurality of cushioning areas.

However, the total cushioning area of the smaller bladders 14, 15, and16 is less than the original of the larger bladder 1, and the ribs 11form a plurality of vertical walls 110 around each of the small bladders14, 15, and 16 that may cause the wearer feel pain when some smallerbladders 14 in the central portion become bottom out under some heavyheel impact.

The smaller bladder 14 in the central area can be made softer to comfortthe heel of the wearer during taking a normal walking exercise; howeverthis would cause the smaller bladder 14 tends to bottom out in normalrunning activity. If the smaller bladder 14 contains a higher innerpressure to provide adequate shock absorption for running, it wouldcause the wearer to feel it is too hard and suffer a pain from thebladder 14 in a normal walking.

In order to perfect the heel cushion in different athletic activities,such as walking and running, there is a need to improve the cushioningfunction at shoe mid-sole.

SUMMARY OF THE INVENTION

In order to perfect the heel cushioning design for athletic activities,the present invention provides an air cushion assembly and a fabricationmethod for producing such a cushion assembly. The air cushion assemblyaccording to the present invention contains an air bladder associatedwith a cushioning element in a vertical stack configuration, so as toabsorb a lighter heel impact and heavier heel impact sequentially.

The air bladder of the air cushion assembly may contain a lower innerpressure for providing a softer shock absorption during a wearer takingwalking exercise, and the cushioning element may be an air bladder withhigher inner pressure or a cushion which made from a resilient elementfor absorbing some other heavier heel impacts, such as running orplaying ball, or the likes.

In one aspect of the present invention, an air cushion for cushioning ina shoe with multistage shock-absorbing assembly includes a first airbladder, having an inner wall which contains a first inner pressure, theinner wall having an upper surface and a lower surface, a tying element,having an upper side which is connected to the upper surface of theinner wall of the first air bladder, and a lower side; and a cushioningelement, having an upper side connected to the lower side of the tyingelement and a lower side connected to the lower surface of the innerwall of the first air bladder, thereby forming a vertical stackconfiguration for absorbing heel impact in a mid-sole sequentially, suchthat when the impact lighter than a predetermined value is applied tothe vertical stack configuration, it is absorbed by deforming the firstair bladder only, and when the impact heavier than the predeterminedvalue is applied to the vertical stack configuration, it is absorbed bydeforming both the first air bladder and the cushioning element.

The air cushion for cushioning in a shoe with multistage shock-absorbingassembly may further include an upper frame and a base frame for fixingthe first air bladder therebetween.

In one embodiment, the cushioning element is a resilient pad. The tyingelement is a plurality of inward protruding walls formed on the uppersurface of the inner wall of the first air bladder, connected to theupper side of the cushioning element for keeping the first air bladderin a predetermined shape.

In one embodiment, the tying element has a pile of yarns, fabric orfibers which is glued between the first air bladder and the cushioningelement, for keeping the first air bladder in a predetermined shape.

In one embodiment, the cushioning element includes a second air bladderwhich contains a second inner pressure.

In one embodiment, the second air bladder contains a tying elementformed with a plurality of inward protruding walls for keeping thesecond air bladder in a predetermined shape thereof.

In another aspect, the present invention relates to an air cushion forcushioning in a shoe with multistage shock-absorbing assembly. In oneembodiment, the air cushion has a first air bladder, having an innerwall which contains a first inner pressure, the inner wall having anupper surface and a lower surface, and a cushioning element, disposed inrelation to the first air bladder to form a vertical stack configurationtherewith such that when the impact lighter than a predetermined valueis applied to the vertical stack configuration, it is absorbed bydeforming the first air bladder only, and when the impact heavier thanthe predetermined value is applied to the vertical stack configuration,it is absorbed by deforming both the first air bladder and thecushioning element.

In one embodiment, the cushioning element is a second air bladder whichcontains a second air pressure. The air cushion may further have aresilient pad disposed on the upper side of the first air bladder.

In another embodiment, the cushioning element has a second air bladderand a resilient pad.

In yet another embodiment, the cushioning element is a resilient pad.

In a further embodiment, the cushioning element is a bladder containinga gel.

In yet a further embodiment, the cushioning element is a bladdercontaining a granules cushioning material.

In yet another aspect, the fabrication method of the air cushionassembly according to the present invention includes the steps ofblowing a melting inflatable bladder or tube together with a cushioningelement in a blowing mold, inflating the melting inflatable bladder withair in high pressure, so as to form a bladder with a passage way thatconfirming the inner shape of the blowing mold, and blowing air into thebladder in a preset inner pressure; and thereafter sealing the passageway for forming an air cushion with multistage shock-absorbing assembly.

Further scope of the applicability of the present invention will becomeapparent from the detailed description given hereinafter. However, itshould be understood that the detailed description and specificexamples, while indicating preferred embodiments of the invention, aregiven by way of illustration only, since various changes andmodifications within the spirit and scope of the invention will becomeapparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description given hereinbelow and the accompanying drawings,which are given by way of illustration only, and thus are not limitativeof the present invention, and wherein:

FIG. 1 is a schematic view showing the steps of a conventional methodfor producing an air cushion;

FIG. 2 is a schematic view showing the steps of a fabrication method ofan air cushion according to one embodiment of the present invention;

FIG. 3 is a schematic view showing the steps of a fabrication method ofan air cushion according to another embodiment of the present invention;

FIG. 4 is a schematic view showing the variety of deformation of an aircushion in different impact loading, explaining the reason to associatean air bladder to a cushioning element in a vertical stackconfiguration, according to one embodiment of the present invention;

FIG. 5 shows schematically a cross-sectional view of an air cushionaccording to one embodiment of the present invention;

FIG. 6 shows schematically a cross-sectional view of an air cushionaccording to another embodiment of the present invention;

FIG. 7 shows schematically a cross-sectional view of an air cushionaccording to yet another embodiment of the present invention;

FIG. 8 shows schematically a cross-sectional view of an air cushionaccording to a further embodiment of the present invention;

FIG. 9 shows schematically a cross-sectional view of an air cushionaccording to yet a further embodiment of the present invention;

FIG. 10 shows schematically a cross-sectional view of an air cushionaccording to an alternative embodiment of the present invention;

FIG. 11 shows schematically a cross-sectional view of an air cushionaccording to one embodiment of the present invention;

FIG. 12 shows schematically a cross-sectional view of an air cushionaccording to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 2 and 5, a fabrication method of an air cushionassembly according to one embodiment of the present invention includesthe steps of inserting a melting inflatable bladder 40 or tube (notshown) together with a cushioning element 22 in a blowing mold 3 havingan upper side, and an opposite, lower side, an exterior surface and aninterior surface, inflating the melting inflatable bladder 40 with airin high pressure, so as to form a bladder 41 with a passage way 42conforming to the inner shape of the blowing mold 3, and blowing airinto the bladder 41 in a first inner pressure; and thereafter sealingthe passage way 42 for forming a first air cushion 4 which connects thecushioning element 22 on one side. The resulting air cushion withmultistage shock-absorbing assembly includes a stacked structure of theupper side of the blowing mold 3, the melting inflatable bladder 40, thecushioning element 22, and the lower side of the blowing mold 3 as shownin FIG. 2.

Preferably, in one embodiment, the cushioning element 22 may have glueor adhesive layer for bonding itself onto the lower side of the meltinginflatable bladder 40 such that the resulting air cushion withmultistage shock-absorbing assembly includes a stacked structure of theupper side of the blowing mold 3, the melting inflatable bladder 40, thecushioning element 22, and the lower side of the blowing mold 3 as shownin FIG. 2. In an alternative embodiment as shown in FIG. 3, thecushioning element 22 is connected to the interior surface of themelting inflatable tube 50 or bladder (not shown) and disposed into theblowing mold 30 together. The melting inflatable tube 50 comprises afirst inner wall 501 and a second inner side 502.

The inner surface of the blowing mold 30 may comprise a plurality ofinward protruding portions 31 for forming a bladder 51 with a pluralityof indents or holes 52 and a passage way 53. While blowing air into thebladder 51 in a preset pressure; and thereafter sealing the passage way53, it is forming an air cushion 5 with multistage shock-absorbingassembly. The walls of the indents or holes 52 have one end connectedwith the cushioning element 22, so as to inhibit bulging effect and keepthe air cushion 5 in a predetermined shape.

Referring to FIG. 4, an air cushion 6 of an embodiment of the presentinvention for absorbing heel impacts in different athletic activities.The air cushion 6 has a cushioning element 22 disposed within an airbladder 60 at the bottom side 222 thereof, to form a vertical stackconfiguration for providing cushioning force against the heel impactssequentially. The cushioning element 22 can be a resilient pad whichcontains a second cushioning material 221, such as liquid, gelcushioning material, air in high pressure, granules cushioning material,polyester elastomer or the like.

The air bladder 60 has an upper surface 61 for absorbing some lighterimpacts 66 and 67 in walking exercise. When a wearer is walking, theheel strike yielding a plurality of impacts ranging from 0 to 1.5 timesthe body weight, therefore the heel imposes the impacts 66 or 67 ontothe upper surface 61. In other words, a slighter impact 66 or 67 isabsorbed by the deformation of the (first) air bladder 60 only. As theupper surface 61 provides cushioning effect on the heel with no rib,therefore the wearer would feel comfortable without paining caused bythe ribs and the vertical walls of the conventional air cushion as beingdepicted in FIG. 1.

When the wearer is running or taking some other strenuous activities,the impact 68 may increase up to 2-3 times the body weight, this causesthe air bladder 60 to be bottom out and deforms the upper portion of thecushioning element 22. By this way, while the air bladder 60 is bottomout, the cushioning element 22 provides a cushioning force to protectthe heel from injury. In other words, a higher impact 68 is absorbed bythe deformations of both the air bladder 60 and the cushioning element22 together.

According to the present invention, as illustrated in FIG. 4, the airbladder 60 and the cushioning element 22 form a vertical stackconfiguration for absorbing heel impact in a mid-sole sequentially. Forthis arrangement, when the impact lighter 66 or 67 than a predeterminedvalue is applied to the vertical stack configuration, it is absorbed bydeforming the first air bladder 60 only, and when the impact 68 heavierthan the predetermined value is applied to the vertical stackconfiguration, it is absorbed by deforming both the first air bladder 60and the cushioning element 22. The predetermined value can be determinedby the design specification of an air cushion, such as materials and thefirst and/or second air pressures in the first air bladder 60 and thecushioning element 22, respectively. For example, in one embodiment, thepredetermined value is 1.5 times of the averaged human weight.

Referring to FIG. 6, an air cushion 4′ comprises a first air bladder 41′and a resilient pad 43. The air bladder 41′ provides a softer cushioningforce for cushioning lighter impacts from a wearer's walking exerciseuntil being bottom out, and provides cushioning force together with theresilient pad 43 to absorb some stronger impacts from running or someother strenuous athletic activities.

Referring to FIG. 7, an alternative embodiment of air cushion 4″comprises a first air bladder 41″ and a cushioning element 22 in avertical stack configuration. The cushioning element 22 comprises aresilient pad 225 combined or attached with a second air bladder 226which contains a second inner pressure. The first air bladder 41″contains a first inner pressure relatively lower than the second innerpressure thereby to absorb the impact on wear's heel from walking untilbeing bottom out; and thereafter to absorb even much stronger impacttogether with the second air bladder 226. Once the first air bladder 41″and the second air bladder 226 are sequentially becoming bottom out, theresilient pad 225 provides a resilient force to buffer the impact,thereby to protect the wearer from possible lower extremity injuries.

Referring to FIG. 8, an alternative embodiment of air cushion 71 withmultistage shock-absorbing assembly, comprises an air bladder 710 with acushioning element 711 disposed therein, and a resilient pad 712attached thereon. The cushioning element 711 may be a bladder filledwith gel, foam, a particulate material, a liquid, or the like. Theresilient pad 712 may be an air bladder, a polyester elastomer, fabric,a bladder filled with gel, foam, a particulate material, a liquid, orthe like.

Referring to FIG. 9, a further alternative embodiment of air cushion 72with a multistage shock-absorbing assembly, comprises a first airbladder 721 having an inner wall which contains a first inner pressure,the inner wall having an upper surface and a lower surface, a second airbladder 722, and a plurality of tying elements 723, that connectedtherebetween in a vertical stack configuration. The second air bladder722 has one side attached to the lower surface of the inner wall of thefirst air bladder 721, and other side coupled to the upper surface ofthe inner wall of the first air bladder 721 via the plurality of tyingelements 723, so as to keep the outer surface in flatten or in apredetermined shape without bulging out accidentally. The plurality oftying elements 723 can be a pile of yarns or fabric which is gluedbetween the inner wall of the and the first air bladder 721 and theoutside of the second air bladder 722 for eliminating possible bulgingeffect on outside of the air cushion 72. The first air bladder 721, thesecond air bladder 722 and the plurality of tying elements 723 aredisposed in a vertical stack configuration for absorbing heel impact ina mid-sole sequentially. Accordingly, when the impact lighter than apredetermined value is applied to the vertical stack configuration, itis absorbed by deforming the first air bladder 721 only, and when theimpact heavier than the predetermined value is applied to the verticalstack configuration, it is absorbed by deforming both the first airbladder 721 and the second air bladder 722.

Referring to FIGS. 4 and 10, a simplified alternative embodiment of aircushion 73 with a multistage shock-absorbing assembly, comprises a firstair bladder 731 encapsulated in a second air bladder 732 in a verticalstack configuration.

Referring to FIG. 11, a refined alternative embodiment of air cushion 74with a multistage shock-absorbing assembly, comprises a first airbladder 741, a cushioning element 742, a upper frame 743, and a baseframe 744 in a vertical stack configuration.

Referring to FIG. 11, the cushioning element 742 may be resilient padattached on the lower inner side of the first air bladder 741. The firstair bladder 741 is contained the cushioning element 742 and can be fixedbetween the upper frame 743 and the base frame 744. The first airbladder 741 is formed with a plurality inward protruded walls 7410connected with the outer surface of the cushioning element 742 foracting as tying element to eliminate bulging of the upper surface of theair cushion 74.

Referring to FIG. 12, the cushioning element 80 with a multistageshock-absorbing assembly, comprises a first air bladder 81, a tyingelement 811, and a second air bladder 82. The tying element 811 isconnected between the inner side of the first air bladder 81 which has afirst passage way for fill into a first inner pressure P1, and theoutside of the second air bladder 82. The second air bladder 82 has aplurality of tying elements 821 formed therein, and a second passage wayfor fill compressible fluid into a second inner pressure P2. Preferably,the second inner pressure P2 of the second air bladder 82 is relativehigher than the first inner pressure P1, thereby to absorb lighterimpacts in normal walking exercise by the first air bladder 81, andabsorb even more heaver impacts in running or strenuous athleticactivity together with the second air bladder 82.

The tying elements 821 may be a plurality of inward protruding wallswhich connect the upper and lower inner walls of the second air bladder82 and keep the outer surface of the second air bladder 82 in apredetermined shape.

The inward protruding walls functioning as tying elements 821 may beformed by a blowing mold with small pins that forming a plurality ofindent or small holes on the second air bladder 82.

Accordingly to embodiments of the present invention, as shown in FIGS. 9to 12, when a small impact is loaded, only the first air blade 721, 73,741 and 81 shall be deformed to absorb such a small impact. However,when a bigger impact is loaded, the first air blade 721, 73, 741 and 81and the cushioning element 722, 732, 742, and 82 shall be deformed toabsorb the bigger impact together.

While the invention has been described by way of example and in terms ofpreferred embodiments, it is to be understood that the invention is notlimited thereto. On the contrary, it is intended to cover variousmodifications and similar arrangements and procedures, and the scope ofthe appended claims therefore should be accorded the broadestinterpretation so as to encompass all such modifications and similararrangements and procedures.

1. An air cushion for cushioning in a shoe with multistageshock-absorbing assembly, comprising: a first air bladder, having aninner wall which contains a first inner pressure, the inner wall havingan upper surface and a lower surface; a tying element, having an upperside which is connected to the upper surface of the inner wall of thefirst air bladder, and a lower side; and a cushioning element, having anupper side connected to the lower side of the tying element and a lowerside connected to the lower surface of the inner wall of the first airbladder, thereby forming a vertical stack configuration for absorbingheel impact in a mid-sole sequentially, such that when the impactlighter than a predetermined value is applied to the vertical stackconfiguration, it is absorbed by deforming the first air bladder only,and when the impact heavier than the predetermined value is applied tothe vertical stack configuration, it is absorbed by deforming both thefirst air bladder and the cushioning element.
 2. The air cushion forcushioning in a shoe with multistage shock-absorbing assembly of claim1, wherein the cushioning element comprises a resilient pad.
 3. The aircushion for cushioning in a shoe with multistage shock-absorbingassembly of claim 2, wherein the tying element comprises a plurality ofinward protruding walls disposed between the upper surface of the innerwall of the first air bladder and the upper side of the cushioningelement for keeping the first air bladder in a predetermined shape. 4.The air cushion for cushioning in a shoe with multistage shock-absorbingassembly of claim 1, wherein the tying element comprises a pile ofyarns, fabric or fibers which is glued between the first air bladder andthe cushioning element, for keeping the first air bladder in apredetermined shape.
 5. The air cushion for cushioning in a shoe withmultistage shock-absorbing assembly of claim 1, further comprising anupper frame and a base frame for fixing the first air bladdertherebetween.
 6. The air cushion with multistage shock-absorbingassembly of claim 1, wherein the cushioning element comprises a secondair bladder which contains a second inner pressure.
 7. The air cushionfor cushioning in a shoe with multistage shock-absorbing assembly ofclaim 6, wherein the second air bladder contains a tying element formedwith a plurality of inward protruding walls for keeping the second airbladder in a predetermined shape thereof.
 8. An air cushion forcushioning in a shoe with multistage shock-absorbing assembly,comprising: a first air bladder, having an inner wall which contains afirst inner pressure, the inner wall having an upper surface and a lowersurface; and a cushioning element, disposed in relation to the first airbladder to form a vertical stack configuration therewith such that whenthe impact lighter than a predetermined value is applied to the verticalstack configuration, it is absorbed by deforming the first air bladderonly, and when the impact heavier than the predetermined value isapplied to the vertical stack configuration, it is absorbed by deformingboth the first air bladder and the cushioning element.
 9. The aircushion for cushioning in a shoe with multistage shock-absorbingassembly of claim 8, wherein the cushioning element is a second airbladder which contains a second air pressure.
 10. The air cushion forcushioning in a shoe with multistage shock-absorbing assembly of claim9, further including a resilient pad disposed on the upper side of thefirst air bladder.
 11. The air cushion for cushioning in a shoe withmultistage shock-absorbing assembly of claim 8, wherein the cushioningelement comprises a second air bladder and a resilient pad.
 12. The aircushion for cushioning in a shoe with multistage shock-absorbingassembly of claim 8, wherein the cushioning element is a resilient pad.13. The air cushion for cushioning in a shoe with multistageshock-absorbing assembly of claim 8, wherein the cushioning element is abladder containing a gel.
 14. The air cushion for cushioning in a shoewith multistage shock-absorbing assembly of claim 8, wherein thecushioning element is a bladder containing a granules cushioningmaterial.